Crating kit for a two-wheeled vehicle

ABSTRACT

A kit-crate made for a two-wheeled vehicle includes a pallet providing a wheel well and a plurality of well blocks adapted for insertion into the wheel well for wedging a wheel of the two-wheeled vehicle in the wheel well. A pair of end panels; a set of four side panels comprising two lower side panels and two upper side panels; and a cover panel are provided to assembly a crate around the vehicle. The end panels and the two lower side panels are adapted for engagement with the pallet to form a rigid open box structure. The two upper side panels are adapted for engagement with the end panels and respective lower side panels for further completing the open box structure and the cover panel is adapted for engagement with the end panels and the two upper side panels for completing the crate.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to commercial pallets and crates for shipping goods, and more particularly to a specialized crate system enabling use as a drop-off kit for assembly by untrained persons in shipping a motorcycle or other two-wheeled vehicle.

[0003] 2. Description of Related Art

[0004] The following art defines the present state of this field:

[0005] Clark et al., U.S. Pat. No. 3,877,602 describes a collapsible container, formed of a plurality of light-weight, insulating panel members for preserving perishables during shipping and storage. The panel members are detachably secured together along their respective edges by novel fastener assemblies, each comprising a stud formed of a synthetic plastic material and a stud-receiving element formed of a softer synthetic plastic material to lock the stud in the fully fastened condition. A pallet, associated with a loaded container, serves as a skid in receiving the disassembled panel members in a knocked down, nested condition.

[0006] Holden, U.S. Pat. No. 5,626,241 describes a storage and inspection rack for wheel and tire assemblies. The inspection rack includes an exterior tubular metal framework, a removable fire retardant protective cover and roller carriage assemblies. The frame provides a plurality of individual bays. Each bay houses a roller carriage assembly for easy loading and unloading of the wheel and tire assembly which stand upright therein.

[0007] Pruitt, Jr., U.S. Pat. No. 5,669,507 describes a collapsible pallet box or container composed of a pallet platform and four upright panels connected together at the corner edges by flexible material to form a polygon expandable to a rectangle or collapsible to a flattened parallelogram. The bottoms of the polygon panels are removably attached to the pallet. The tops of the panels have a stabilizing grid with interconnected compression elements between the panels to stabilize the panel tops in the expanded rectangular configuration, and interconnectable, releasable hook and loop fasteners on the grid and on the polygon upper end, at the corners of the grid and recessed into the corners of the polygon, to keep the grid secured to the polygon and thereby keep the polygon locked to the pallet.

[0008] Heil, U.S. Pat. No. 6,006,675 describes a pallet for a wheeled item comprising a base frame having openings for receiving forklift arms, a plurality of tracks mounted on the base frame for receiving the wheels of the item, and a plurality of ramps mounted on the base frame and sloping from the tracks toward the base frame so that when the wheeled item is shifted on the wheels from the tracks along the ramps, the undercarriage of the wheeled item comes to rest on the pallet. Wheeled items can be quickly loaded and secured on the pallet and can be manipulated with a forklift for storing wheeled items in stacked relation. The pallet can be designed to store wheeled items with aligned or offset casters.

[0009] Creek et al., U.S. Pat. No. 6,006,676 describes a packaging skid or pallet having a base including a bottom surface, two side surfaces and two end surfaces. A pair of longitudinally extending channel members are secured to the base and define cavities for receiving lifting forks associated with a lift truck. A number of transversely extending cross members are secured to the channel members and/or the base. A first support tray is fixed to the base between the channel members and two cross member for receiving and retaining a front wheel associated with a motorcycle. A second support tray is fixed to the base between the channel members and two different cross members. A chock is positioned within the second support tray to support a back wheel of the motorcycle. The chock can be repositioned within the second support tray to accommodate motorcycles having different wheelbases. The components of the skid are formed from light-weight, rolled steel to resist corrosion and to reduce weight compared to a comparable wooden skid.

[0010] Heil, U.S. Pat. No. 6,263,806 describes a pallet for a wheeled item comprising a base frame having openings for receiving forklift arms, a plurality of tracks mounted on the base frame for receiving the wheels of the item, and a plurality of ramps mounted on the base frame and sloping from the tracks toward the base frame so that when the wheeled item is shifted on the wheels from the tracks along the ramps, the undercarriage of the wheeled item comes to rest on the pallet. Wheeled items can be quickly loaded and secured on the pallet and can be manipulated with a forklift for storing wheeled items in stacked relation. The pallet can be designed to store wheeled items with aligned or offset casters.

[0011] Weber, WO 01/04010 A1 describes a pallet comprising an accommodating channel, which extends in a longitudinal direction of the pallet, which is open toward the upper side of the pallet, and which is provided for adjusting and holding a two-wheeler. The pallet also comprises at least one accommodating space for holding and transporting the pallet with the aid of at least one fork or of at least one similar means of a transport or lifting device. The at least one accommodating space is transversally arranged with regards to the longitudinal direction of the pallet and extends continuously on both sides of the accommodating channel. The holding and transporting of the pallet by a fork lifter or a similar device is improved since the forks of the fork lifter engage inside the accommodating spaces in a manner that is transversal to the longitudinal direction of the pallet, and they can receive the pallet without damaging the motorcycle.

[0012] The prior art teaches collapsible containers, specialty racks, pallet and crate construction, pallets for wheeled vehicles, skids and pallets with accommodating wheel wells, and pallets especially constructed for accommodating a two-wheeled vehicle; but does not teach the specialty pallet-crate kit of the present invention in general and the apparatus for positioning and locking the steered wheel of a motorcycle during shipment. The present invention fulfills these needs and provides further related advantages as described in the following summary.

SUMMARY OF THE INVENTION

[0013] The present invention teaches certain benefits in construction and use which give rise to the objectives described below.

[0014] A kit-crate made for a two-wheeled vehicle includes a pallet providing a wheel well and a plurality of well blocks adapted for insertion into the wheel well for wedging a wheel of the two-wheeled vehicle to prevent movement during shipping and to allow a lower profile enabling a lower crate height. A pair of end panels; a set of four side panels comprising two lower side panels and two upper side panels; and a cover panel are provided to assembly a crate around the vehicle. The end panels and the two lower side panels are adapted for engagement with the pallet to form a rigid open box structure. The two upper side panels are adapted for engagement with the end panels and respective lower side panels for further completing the open box structure and the cover panel is adapted for engagement with the end panels and the two upper side panels for completing the crate. Tongue-in-groove construction is preferably used to position and place the several panels. Straps are set around the finished crate to enable rigidizing of the assembly during shipping. The entire crate may be disassembled and stored as a flat stack taking little storage space and it may thereafter be reused without the difficulty of nails, nail holes and splintered wood. The benefit of using one or more blocks to wedge the wheel into the wheel well enables the well to be made longer and wider than would be desired if only a specific wheel wide and diameter were being used with the kit. A wider and longer well enables the kit to accommodate a wide range of wheel widths and diameters yet any size wheel may be wedged using the appropriate size and number of blocks.

[0015] A primary objective of the present invention is to provide an apparatus and method of use of such apparatus that provides advantages not taught by the prior art.

[0016] Another objective is to provide such an invention capable of being shipped as a knocked-down stacked kit to be assembled without tools.

[0017] A further objective is to provide such an invention capable of being stored and shipped in a stacked manner.

[0018] A still further objective is to provide such an invention capable of mounting a vehicle on a pallet with one wheel wedged in place.

[0019] Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The accompanying drawings illustrate the present invention. In such drawings:

[0021]FIG. 1 is a perspective view of the preferred embodiment of the present invention crate-kit as knocked-down for shipment to a customer for assembly;

[0022]FIG. 2 is a perspective view of a pallet thereof with a motorcycle for shipment strapped thereto;

[0023]FIG. 3 is an exploded perspective view showing the portions of a crate thereof; and

[0024]FIG. 4 is a perspective view thereof showing the invention as assembled and ready for shipping the motorcycle.

DETAILED DESCRIPTION OF THE INVENTION

[0025] The above described drawing figures illustrate the invention in at least one of its preferred embodiments, which is further defined in detail in the following description.

[0026] The present invention is a kit-crate apparatus. A pallet 10, as shown in FIG. 1 provides a wheel well 20 at one end. A two-wheeled vehicle 30, preferably a motorcycle or a bicycle is mounted on the pallet 10 with one wheel 32 inserted into the wheel well 20. A plurality of well blocks 40 are adapted for insertion into the wheel well 20 for wedging the wheel 32 in the wheel well 20. To accomplish this, one or more of the well blocks 40 may be used. By forcing the wheel 32 to be in compression between the walls of the well 20 or between the blocks 40 or between the walls of the well 20 and the blocks 40, it is possible to prevent the wheel 32 from turning during shipment. Another advantage of this construction is the ability to place the wheel 32 at a desired location within the well 20 thereby locating the center of mass of the vehicle at the most appropriate location relative to the pallet which it is being shipped. This is important in assuring that the package is balance for pickup and movement by a fork list truck or other warehousing apparatus. The vehicle 30 may be shipped on the pallet 10 without an enclosing crate, or it may be crated as is described below.

[0027] The crate comprises: a pair of end panels 50 of a height superior to that of the vehicle 30; a set of two or more side panels comprising preferably, two lower side panels 60 and two upper side panels 70; and a cover panel 80. The end panels 50 and the two lower side panels 60 are adapted for engagement with the pallet 10 to form a rigid open box structure around the vehicle 30 using spring clips 5. See FIG. 4. The two upper side panels 70 are engaged with the end panels 50 and respective lower side panels 60 using spring clips 5, for further completing the open box structure whereby the lower 60 and upper 70 side panels reach a height superior to that of the vehicle 30. The cover panel 80 is adapted for engagement with the end panels 50 and the side panels 70 for completing the crate, and it is rigidized by encircling straps 8, as shown in FIG. 4.

[0028] The reason for splitting the two sides of the crate into the upper and the lower side panels is to enable the side panels 60, 70 to be stacked on top of the pallet 10 without the side panels being wider than the pallet 10, as is shown in FIG. 1.

[0029] To enable an unskilled person to assemble the crate onto the pallet, the several panels are made to engage without nails or other fasteners and may be assembled without any tools whatever. This may be accomplished in several ways, but the preferred manner of engagement of the several panels is by tongue in groove construction, as shown. Such is accomplish by forming a groove in one of the engaging parts, and a tongue in the mating part. Such interlocking tongue-in-groove construction is well known in the art. However, other engagement means for positioning and interconnecting the several panels with each other and with the pallet will be know to those of skill in the art.

[0030] Preferably, the pallet provides a peripheral groove 12 and the end panels 50 and the lower side panels 60 each provide a tongue 14 for insert, interlocking engagement with the peripheral groove 12 so that the end panels 50 and lower side panels 60 are assembled to the pallet in preferred and determined locations. Likewise, the upper side panels 70 each engage with the lower side panels 60 in the same manner. The cover 80 is mounted on top of the end panels 50 and the upper side panels 70 by pressing tongues 14 into grooves in the cover panel 80. The finished crate is bound using spring clamps 5 on each corner and tightening straps 8 encircling it so that it is held tightly together during shipment.

[0031] While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims. 

What is claimed is:
 1. A kit-crate apparatus for a two-wheeled vehicle comprising: a pallet providing a wheel well and a plurality of well blocks adapted for insertion into the wheel well for wedging a wheel of the two-wheeled vehicle in the wheel well to achieve stability of the vehicle on the pallet; and stacked and tied down to the pallet for shipping as an integral bundle: a pair of end panels; a set of side panels; and a cover panel; the pallet and the panels providing engagement means for mutual engagement therebetween thereby forming a rigid open box structure, the cover closing the box structure for enclosing the vehicle for shipping.
 2. The apparatus of claim 1 wherein the pallet provides a peripheral groove and the end panels and the side panels each provide a lower tongue for interlocking engagement with the peripheral groove so that the end panels and side panels are placed correctly on the pallet without tools.
 3. The apparatus of claim 2 further comprising a plurality of spring clips adapted for engaging corners of the panels for rigidizing the apparatus.
 4. The apparatus of claim 1 further comprising a means for strap tie-down of the two-wheeled vehicle.
 5. A kit-crate apparatus comprising in combination: a pallet providing a wheel well; a two-wheeled vehicle mounted on the pallet with one wheel inserted into the wheel well; a plurality of well blocks forced into the wheel well thereby wedging the one wheel of the two-wheeled vehicle in the wheel well; a pair of end panels of a height superior to that of the vehicle; a set of four side panels comprising two lower side panels and two upper side panels; and a cover panel; the end panels and the two lower side panels adapted for engagement with the pallet to form a rigid open box structure around the vehicle, the two upper side panels adapted for engagement with the end panels and respective lower side panels for further completing the open box structure whereby the lower and upper side panels reach a common height superior to that of the vehicle; and the cover panel adapted for engagement with the end panels and the two upper side panels for closing the apparatus; a set of straps encircling the apparatus for rigidizing thereof.
 6. The apparatus of claim 5 wherein the pallet provides a peripheral groove and the end panels and the lower side panels each provide a lower tongue in interlocking engagement with the peripheral groove so that the end panels and lower side panels are assembled to the pallet without tools, the cover panel providing a further peripheral groove and the end panels and the upper side panels providing an upper tongue in interlocking engagement with the further peripheral groove thereby setting the cover in place and engaged with the end panels and the upper side panels.
 7. The apparatus of claim 6 further comprising a plurality of spring clips adapted for engaging corners of the panels for interengaging the several panels of the apparatus, and a plurality of encircling straps positioned around the apparatus for further rigidizing the apparatus.
 8. The apparatus of claim 5 further comprising a means for strap tie-down of the two-wheeled vehicle to the pallet.
 9. An apparatus for shipping a vehicle comprising: a pallet providing a wheel well and a plurality of well blocks, the well blocks adapted for insertion into the wheel well for wedging a wheel of the vehicle in the wheel well; the wheel well, blocks and the wheel of the vehicle related and positioned so that the wheel is immobily wedged to achieve stability and preferred positioning of the vehicle on the pallet. 